Composite board



3 Sheets-Sheet I 1' Filed March 27. 1929 INVENTOR 0 dflfi bfias' BY 5M ATTORNEY Aug. 23, 1932. Q, HEPPES k 1,873,887

COMPOS ITE BOARD Filed March 27. 1929 5 Sheets-Sheet 2 ATTORNEY 0. A. HEPPES COMPOS ITE BOARD Filed March 27. 1929 Aug. 23, 1932.

3 Sheets-Sheet 5 .cu-roFF v ICUTOFF ATTORNEY Patented Au 23, 1932 UNITED STATES PATENT OFFICE or'ro A. Burns, or m. GRANGE, ILnI'NoIs, ASSIGNOR, BY n'msNn ASSIGNMENTS, TO THE PATENT AND LICENSING CORPORATION, or BOSTON, MASSACHUSETTS, A. con- POBATION OF MASSACHUSETTS COMPOSITE BOARD Application flied March 2'7, 1929. Serial No. 350,268.

This invention relates to composition board of a rigid and more or less waterproof nature which can be inexpensively produced and which is suitable for use as wall board, siding,

' I or as binder boards for packaging asphaltic composition roofing shingles in bundles, as well as for other purposes. The invention will be described particularly with reference to the use of my novel board construction as we substitute for the wooden boards hitherto used for packaging composition roofing shingles, whereby the cost of packaging these shingles may be substantially lessened and whereby the liability of splitting or cracking is of the wooden boards, as well as other objections thereto, maybe eliminated. The adaptability of the board constructed in accord ance with the invention, to other uses, as well as the manner in which it can be so used, will an be readily apparent to those skilled in the art.

In carrying the invention into practise, the boards are preferably formed from a plastic composition consisting primarily of fiber and 2E bitumen, the boards being fabricated in suitable dimensions, and provided-with edge reinforcements which may-be in any of a num ber of forms. Where the boards are. to be used as cover boards for shingle bundles, some form of edge reinforcement is necessary in order to prevent the tying wires from penetrating the cover boards, and to this end, I may use strips of wood, metallic wear pieces, strands of tough fiber or similar reinforcing elements'associated with edge portions of the boards, as will presently be described.

The invention, in several embodiments thereof, will be more fully apparent from the following description and the accompanying drawings, in which Figure 1 illustrates, mastic composition prior .to wrapplng the ppkme in an outer sheathing of paper or the e Figure 2 is a view similar to Figure 1 showing the completed board structure,

Figure 2a is a transverse cross-section taken along line 2a'2a of Figure 2,

Figure 3 is a longitudinal section through the board shown in Figure 2,

in plan, a board of Figure 4 is a view of a bundle of shingles with cover boards of thet pe shown in Figures 1 to 3, but with a mo ified arrangement of reinforcing means,

Figure 5 is a transverse sectional view through the coverboards of Figure 4,

Figure dis a view similar to Figure 4 but showing a modified form of reinforcing means,

Figure 7 is a fragmentary view of a further modified form of reinforcing means,

Figure 8 shows a partial section of a bundle with the reinforcing means of Figure 7 in place,

Figure 9. shows still another form of reinforcing means,

" Figure 10 shows, in perspective, still another modification of the reinforcing means,

Figure 11 is a plan view of a bundle wherein the reinforcing means of Figure 10 are employed, A

Figure 12 is a view in perspective of still another modification of theinvention, showing the board prior to complete fabrication,

Figure 13 is a transverse cross-section through the board'of Figure 12, and

Figure 14; is a-plan view, with parts broken away, showing the completely fabricated board structure of Figure 12.

Referring more in detail and particularly Figures 1 to 5, the numeral 10 designates the base of my improved board. This base is composed of a homogeneous mass containing essentially fiber and bitumen such as asphalt. Preferably, and with considerable advantage, the boards are formed by extruding under pressure, a homogeneous plastic mass in a relatively warm state through suitable orifices or dies of the desired configuration, or by forming the plastic mass into boardsbetween suitable compression rolls spaced apart a distance sufficient to produce the desired thickness. In either case, the mastic material may be formed into continuous sheets, which may then be.cut in suitable lengths and widths, this being done preferably'before the composition has completely set and hardened.

In producing the mastic composition from which the boards are to be formed, I preferto the figures,

ably use asphalt of a melting point between 150 and 225 F., and mix therewith, in any suitable type of mixing machine, a quantity of sawdust, or tanbark, or other fibrous material, to ether with relativelyi small amounts of 'ne sand, cork, clay, sawdust, silica, infusorial earth, limestone dust etc., the relative proportions of these ingredients being governed by the character thereof and of the bitumen. In general, the composition willcomprise 20 to 30% asphalt, 10 to 20% fibre and 60 to 70% filler. The composition of the mass should be such that a relatively rigid structure is secured when the boards formed therefrom assume normal atmospheric temperatures. Thus, where relatively soft bitumen is em loyed, relatively larger quantities of the filiie and hardening filler, such as sand, and/or-clay, will be used. With this endin view, I may also, in certain instances, incorporate small quantities of sulphur or the like, with the other ingredients of the mix, so that as the latter is being formed into a plastic mass the elevated tem perature will serve to induce a reaction between the sulphur and the bitumen, thus hardening and stiffening the latter.

Instead of forming the mastic composition as thus described, I may also, with the economic advantages incident thereto, utilize scrap roofing waste of which considerable quantities are generally available at a roofing plant. This scra roofing waste, be-

ing composed largely o fiber and asphalt,

will in many instances, suflice to form a plastic mass of the desired consistency without adding other materials. However, it is usually necessary, or desirable, that further quantities of hard bitumen, fillers, or hardening substances, be mixed with the waste material and the whole ground or masticated to a homogeneous state.

After the plastic mass has been extruded or otherwise formed and cut to desired size, the boards thus formed may be wrapped in facing sheets of kraft paper, or the like. Figure 1 of the drawings show a facing sheet .11 of a width sufficient completely to envelop the board 10, but it should be understood that the facing sheet may be substantially of the same width as the board so as to cover only one face thereof. The facing sheets may be secured to theboards by any convenient adhesive, but preferably, they are united to the board simply by pressure while the board is still warm, since the plastic and sticky naturerof the warm board affords sufficient bonding action firmly to afiix the facing sheets thereto. If desired, the mastic may be calendered directly onto the facing sheets, before the sheet is cut into lengths. 4 y

In order to strengthen and rigidify the edge portions of the board, I associate reinforcing means in various forms and modes,

with the boards. This is particularly desirable where, the boards are used as cover boards for shingle bundles or the like, for otherwise the bundle tie wires would tend to cut through or penetrate the edges of the that the angle pieces as here shown are enclosed by the facing sheet and thereby held in proper place for coaction with the tying wires.

In Figures 4: and 5 the shingle cover boards are formed substantially asshown in Figures 1 to 3, but here the reinforcing means are placed externally of the .facing sheets 11. In the form shown in Figures 4 and 5 the angle pieces 12 are preferably formed of resilient material such as spring steel, so as to enable them to grip the edges of the cover board and remain in proper place for reception of the tying wires 13.

In Figure 6, the reinforcing means consists of strands 14 of rattan, rafiia, or similar tough fibrous material fashioned into angular format-ion around the longitudinal edges of the finished board in the operation of forming the shingle bundle. If desired, strands of this character may be imbedded around the longitudinal edges of the cover boards during the formation thereof and while the mastic composition is still in warm plastic adhesive state so as to form an integral part of the board structure. It will be noted also, in this figure, that only the out ermost face of one of the cover boards 10, has a facing sheet 11 adherent thereto, while the board at the opposite face of the bundle is without a facing sheet and has only the reinforcing strands 14 at the opposite longitudinal edges thereof.

In Figures 7 and 8 the reinforcing means comprises hook-shaped elements 15 formed with pointed prongs 16 which can be driven into the cover boards with slight pressure so as to be thus held in proper place. The reinforcingmembers 15 are also formed on a portion of the outer surface thereof with protrusions or ridges 17 adapted to prevent the tie-wires from slipping therefrom.

Figure 9 illustrates a reinforcing member 18 of a length suificient to enable it to span the entire width of the bundle and formed with angular extensions 19 at its ends and barbs 20 projecting from the surface thereof, which barbs can beforced into the material ofthe cover board. Ridges 'or' protrusions 170; are also formed adjacent the ends of the upper surface of the reinforcing elements 18 to prevent slippage of the tying wires.

In the form shown in Figures 10 and 11,

the reinforcing element comprises short ana fibrous sheet covering and adhering to both gle pieces 21 of metal, formed on the upper the strips and the sheet. Signed at Rutherford, New Jersey, in the county of Bergen this seventh day of March,

surface of one ,of its legs with ridges 17 b and with a barb or prong 22 struck from the intermediate portion of said leg.

In the embodiment of my invention as shown in Figures 12 to .14, the board may be made by feeding a sheet of backing material 25, such as kraft paper, roofing felt or the like, continuously in the direction of its length, the sheet being of a width correspondingsubstantially to the perimeter of the transverse cross section of the board and provided with a coating of adhesive material 26 such as asphalt,'on one of its faces. Narrow wooden reinforcing strips or slats 27, of a thickness corresponding to that of the board to be made, are, fed to the sheet and arranged longitudinally thereon in rows spaced from each other a distance corresponding substantially to the desired width of the board, the strips being held in place by the adhesive material on the coated face of the sheet. Mastic ma terial 28 of the character above referred to may then be fed to the sheet directly from an extruding mechanism, so as to occupy the space between the strips 27, whereupon the marginal portions 29 of the sheet 25, extending beyond the slats are folded over and brought into contact with the upper surface of the mastic layer, sufficient pressure being applied to cause the sheet to adhere securely to the mastic layer. The continuous board thus formed, may then be cut into short length so as to provide boards of desired size with the reinforcing strips at opposite longitudinal edges thereof. When boards of this character are employed in packaging bundles of shin les orthe like, the wooden re- 1 infor'cng str1ps, will effectively prevent cutting or scoring of themain body material of the boards throu h the finding action of the tie-wires, or the like. j s i Iclaim as my invention: 1 1. A cover board for asphaltie shingle bundles comprising a substantially rigid andwater proof slab composed essentially of a homogeneous massrof fiber and bitumen, a-

fibrous facing sheet adherently united to one face of said slab, and reinforcing elements aflixed to said slab along opposite marginal edges thereof.

2. A cover boardfor asphaltic shingle bundles comprising a substantially rigid waterproof slab composed essentially of a homogeneous mass of fiber and bitumen, a fibrous facing sheet adherently united to one.,,face

of saidslab, and reinforcing elements aflixed' to said slab along opposite marginal edges thereof at widely spaced intervals.

3. A cover board for asphaltic shingle bundles comprising a rigid homogeneous slab composed chiefly of fiber and bitumen, narrow wooden strips along the edges thereof and OTTO A. HEPPES. 

